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    L5-Fundamentals of Metal Casting

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    KhayrulIslam
    Casting is a process where molten metal is poured into a mold and solidifies, taking the shape of the mold cavity. It typically occurs in a foundry, which is a factory equipped to handle molten metal and perform the casting process. The main steps are pattern and mold making, melting the metal, pouring it into the mold, allowing it to solidify and freeze, removing it from the mold, and cleaning the finished casting. Casting can create complex shapes in many types of metals and is well-suited for mass production.

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    L5-Fundamentals of Metal Casting

    Uploaded by

    KhayrulIslam
    82 views22 pages
    Casting is a process where molten metal is poured into a mold and solidifies, taking the shape of the mold cavity. It typically occurs in a foundry, which is a factory equipped to handle molten metal and perform the casting process. The main steps are pattern and mold making, melting the metal, pouring it into the mold, allowing it to solidify and freeze, removing it from the mold, and cleaning the finished casting. Casting can create complex shapes in many types of metals and is well-suited for mass production.

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    Casting is a process where molten metal is poured into a mold and solidifies, taking the shape of the mold cavity. It typically occurs in a foundry, which is a factory equipped to handle molten metal and perform the casting process. The main steps are pattern and mold making, melting the metal, pouring it into the mold, allowing it to solidify and freeze, removing it from the mold, and cleaning the finished casting. Casting can create complex shapes in many types of metals and is well-suited for mass production.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    82 views22 pages

    L5-Fundamentals of Metal Casting

    Uploaded by

    KhayrulIslam
    Casting is a process where molten metal is poured into a mold and solidifies, taking the shape of the mold cavity. It typically occurs in a foundry, which is a factory equipped to handle molten metal and perform the casting process. The main steps are pattern and mold making, melting the metal, pouring it into the mold, allowing it to solidify and freeze, removing it from the mold, and cleaning the finished casting. Casting can create complex shapes in many types of metals and is well-suited for mass production.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 22

    Metal

    Casting

    Casting
    Casting is a process in which molten metal flows by
    gravity or other force into a mold where it solidifies in the
    shape of the mold cavity
    Casting is usually performed in
    a foundry
    Foundry = factory equipped
    for making molds, melting and
    handling
    molten
    metal,
    performing
    the
    casting
    process, and cleaning the
    finished casting
    Workers who perform casting
    are called foundrymen

    Steps in casting :

    Pattern and mold making


    Melt the metal
    Pour it into the mold
    Let it freeze
    removing it from the mold
    Cutting off sprues and risers
    Cleaning the component

    Examples of Cast Parts

    Crank handle
    formed by casting;
    some areas were
    machined and
    assembled after
    casting

    C-clamps formed by
    casting (left) and
    machining (right)

    engine blocks

    Capabilities and Advantages of


    Casting
    Can create complex part geometries
    Can create both external and internal shapes
    Some casting processes are net shape (no further manufacturing
    operations are required); others are near net shape
    Can be used with any metal that can be heated to its liquid phase
    All varieties of metals can be cast - ferrous and nonferrous
    Some casting methods are suited to mass production
    Can produce a wide variety of sized parts:

    Large parts (cast parts weighing over 100 tons have been
    made) : engine blocks, wood burning stoves, railway wheels,

    pipes, church bells, statues, etc.


    Small parts: dental crowns, jewelry, small statues, frying pans

    Limitations of Casting
    Different disadvantages for different casting processes:
    Limitations on mechanical properties
    Poor dimensional accuracy and surface finish for some
    processes; e.g., sand casting
    Safety hazards to workers due to hot molten metals
    Environmental problems
    Casting defects which takes place due to lack of
    maintaining casting design guidelines in case of both part
    features design as well as mold design.
    The cost of pattern making, mold design, die design etc.

    Casting process

    Pouring cupMolten metal is


    poured through
    it

    Spruevertical
    portion of the
    gating
    system
    through
    which metals
    enters
    Runnerhorizontal
    channels to
    leads metals
    into main
    cavity

    Riser-additional
    void in the mold
    that provides
    additional metal
    to compensate for
    shrinkage

    Mold cavitycombination of the


    mold material and cores

    Cope- top
    half of the
    pattern

    Dragbottom half
    of the
    pattern

    Heating &Pouring the Metal


    Heating

    Heating furnaces are used to heat the metal to molten


    temperature sufficient for casting

    The heat required is the sum of:

    Heat to raise temperature to melting point

    Heat of fusion to convert from solid to liquid

    Heat to raise molten metal to desired temperature for


    pouring

    Pouring
    For this step to be successful, metal must flow into all regions
    of the mold, most importantly the main cavity, before
    solidifying
    Factors that determine success:
    Pouring temperature
    Pouring rate
    Turbulence

    Fluidity of Molten Metal


    Charateristics of the molten metal

    Fluidity: The capability of a molten metal to fill mold cavities


    Viscosity: Higher viscosity decreases fluidity
    Surface tension: Decreases fluidity; often caused by oxide film
    Inclusions: Insoluble particles can increase viscosity, reducing
    fluidity
    Solidification pattern: Fluidity is inversely proportional to the
    freezing temperature range

    Casitng parameters
    Mold design: The design and size of the sprue, runners, and risers

    affect fluidity
    Mold material and surface: Thermal conductivity and roughness
    decrease fluidity
    Superheating: The temperature increment above the melting point
    increases fluidity
    Pouring rate: Lower pouring rates decrease fluidity because of
    faster cooling
    Heat transfer: Affects the viscosity of the metal

    Fluidity of Molten Metal

    Solidification of Metals
    After the molten metal poured into the mold, a series of events take
    place during the solidification of the casting and its cooling to
    ambient temperature. These events greatly influence the size,
    shape, uniformity, and chemical composition of the grains formed
    throughout the casting, which in turn influence its overall properties.
    Factors affecting these events:

    Type of metal

    Thermal properties of both metal and mold

    Geometric relationship between the volume and the surface area


    of the casting

    The shape of the mold

    Solidification of Metals
    Solidification differs depending on whether the metal is

    A pure element or

    An alloy
    It occurs into two stages:
    Nucleation: Solid particles form within the liquid.
    Crystal growth : The crystal grown at nucleation stage
    starts to grow in crystal growth stage and thus entire liquid
    is turned into solid by extracting heat.

    12

    Cooling Curve for a Pure Metal


    Pure metals solidify at a constant temperature; alloys solidify within a
    temperature range

    Solidification of Pure Metals


    Due to chilling action of mold wall, a
    thin skin of solid metal is formed at
    the interface immediately after
    pouring
    Randomly oriented grains of small size
    form near the mold wall, and large
    columnar grains oriented toward the
    center of the casting form later

    Solidification of Alloys
    Most alloys freeze over a temperature range rather than at a single temperature

    Phase diagram and cooling curve for 50%Ni50%Cu

    Solidification of Alloys
    Characteristic grain
    structure in an alloy
    casting, showing
    segregation of alloying
    components in center of
    casting.

    Casting Alloys

    Ferrous alloys
    cast irons: wear resistance hardness, and good
    machinability
    magnesium base alloys - good corrosion
    resistance and moderate strength
    cast steels - high temperatures required up to
    1650 degree C
    cast stainless steels - have a long freezing range
    and high melting temperatures, high heat and
    corrosion resistance
    Nonferrous alloys
    aluminum base alloys
    copper base alloys
    zinc base alloys
    high temperature alloys

    Metal Solidification: effect of cooling


    rate
    Dendrites
    Tree-like structures that form during the solidification of alloys

    Slow cooling rates produce dendrites with larger branch


    spacing; faster cooling rates produce finer spacing; very fast
    cooling rates produce no dendrites or grains

    Heat Transfer
    An important consideration in casting is the heat transfer
    during the complete cycle from pouring to solidification
    and cooling to room temperature
    Solidification time:
    The metal that solidifies first is at the wall of the mold; this
    solid layer thickens as time passes
    Shrinkage:
    Shrinkage during cooling can change the part dimensions
    and sometimes cause cracking; it is caused by the
    metals thermal expansion properties and the phase
    change between liquid and solid.

    Heat Transfer

    Heat Transfer

    Removal, Cleaning, Finishing and


    Inspection
    After the casting is removed from the mould it is
    thoroughly cleaned and the excess material usually
    along the parting line and the place where the molten
    metal was poured, is removed using a portable grinder.
    White light inspection, pressure test, magnetic particle
    inspection, radiographic test, ultrasonic inspection etc.
    are used

    22

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